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KARACHI MECHANICAL
KARACHI MECHANICAL ENGINEERING WORKS http://karachimechanical.com/contact-us/
Preface
A Pakistan’s execution with European
discipline, the best possible return of
investment in Pakistan made machinery.
Karachi Mechanical & Engineering offers
machinery & components of customer’s
choice, to produce, to improve and to produce
alternative qualities with the help of
customer’s feedback and in house research
and development.
We make it possible by ensuring the quality control, following engineering standards, by
following inspection standards and by using the best possible raw materials, further using
the latest available machinery for tooling and fabrication with great accuracy, as
designer’s demand.
A team work and flawless co ordination, hard working and determination always help us
to meet our target in time and to reduce rejection, further perfect execution of job.
Make customer’s target result comes true we keep ourselves busy all around the
industrial world to bring revolution in Pakistan’s machine building industry.
In order to get improving and improving, we keep in touch with technologists, and
machinery designers not only in Pakistan but Europe and America,
Thanks to Pakistan that we always have a great skills and hard working labors, specially
qualified welders in house, hence we are now able to produce state of the art machinery
at most economical budget.
Simply Karachi Mechanical & Engineering is providing solutions for improvement, with
technology without compromise.
1. Washing
2. Mercerizing
3. Dyeing
4. Skew
5. J-Scary
6. Dry Stack
7. Intermediate Squeezer
8. Fabric Entry & Exits
9. Fluted Profile Turbulence Rollers
10. Padder Sets
11. Chemical Kitchens
12. Storage tanks
KARACHI MECHANICAL
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AQUA POWER SUPER WASH FOR FABRIC
A- Description of Wash box: 1. Roller face 2000 mm 2. Total fabric content 25 meter 3. Double lacing 4. 6N˚ washing compartments with counter flow 5. Wash box made of stainless steel 304 6. Total guider roller N˚21, 16N˚ Plain face, 5N˚ fins profiled
roller, for turbulence 7. Rotary sealing (Beninger design) 8. Indirect heating, steam coil Ǿ 1 ¼” 9. Side total 4 N˚ gas glass windows 10. Top total 2 N˚ Lids 11. Bow roller to open fabric width. 12. Butterfly type compensator with pneumatic loaded pistons. 13. Over flow 14. Drain with butterfly type valve
B- Description of Squeezer mangle capacity 6 Tons: 1. Roller face 2000 mm 2. Upper driven roller rubber covered Ǿ270mm 3. Bottom drive roller ebonite coveredǾ270mm 4. Forged carbon steel mangle material code SA 283 5. Total 4 N˚ taper roller bearings 6. C.I bearing casing 7. All structure e poxy painted 8. Total 2 N˚ pneumatic pistons 9. Showering pipe
C- Electrical board, gear box & motor: 1. Made in Italy, also available assembled in Pakistan; start up can be done in the
presence of European technician with local assistance of KMEW or customer. 2. Description of electrical supplies varies, always directly proportional to process
required, and the No. of boxes offered.
KARACHI MECHANICAL
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AQUA POWER SUPER WASHES FOR ROPE
A- WASHING BOX& SQUEEZER 10 TON.
1. Total rope contents 10 meters approx 2. Reinforced stainless steel box, side 3.5 mm / bottom,
rare, front 2mm / partitions 1.5mm 3. 4 immersed stainless steel bottom rolls diameter 168
mm, assembled on self-aligning Nylon bearings. 4. 3 upper stainless steel guide rolls diameter 168 mm 5. 1 stainless steel draining valve 6. Indirect heating, 7. Drainage and counter-flow connection 8. Stainless steel adjustable guide comb at rope entry,
finger type 9. Feeding pipe for rinsing water supply 10. Vertical 10 t squeeze rollers, the first ebonite Ø350 mm
and the other rubber coated Ø350 mm, pneumatically loaded and foreseen to be driven
11. Angular compensator pneumatically driven for synchronization with the line, potentiometer and sensor are include
12. Steam trap 13. PT 100 sensor 14. Manual glove valve steam supply 15. Manual showering valve 16. Manual butter fly type drain valve 17. Manual butter fly type water intake valve 18. Counter-flow open / close valve included
B- Electrical board, gear box & motor:
1. Made in Italy, also available assembled in Pakistan; start up can be done in the presence of European technician with local assistance of KMEW or customer
2. Description of electrical supplies varies, always directly proportional to process required, and the No. of boxes offered
KARACHI MECHANICAL
KARACHI MECHANICAL ENGINEERING WORKS http://karachimechanical.com/contact-us/
S.F 20 MERCERIZING MACHINE
A Pakistani execution with Italian discipline
KARACHI MECHANICAL
KARACHI MECHANICAL ENGINEERING WORKS http://karachimechanical.com/contact-us/
DENIM FINISHING:
TREATMENT WITH THE SF 20 SUPERFLAT FINISH UNITS
Introduction to the argument
In the last years, and since the introduction of the liquid ammonia process in finishing of Denim by
some market leaders, different machines and processes were tried with the intention of getting
results as similar as possible to those of the ammonia.
Liquid ammonia treated Denim fabrics have certain particular properties, such as:
Clean surface look, luster
Dry and soft hand feel
Higher dimension stability
Very characteristic tone and shade appearance
Reduced crease formation, increased strength
One of the processes that bring some of these properties to Denims, even when not same as liquid
ammonia do, is the treatment of the fabrics with caustic soda (so called Caustification or mercerization
depending on the concentration of Na OH used). Many Denim producers involved in gabardine supply
as well (dyed fabrics) started to use their existing equipment to process Denim with caustic soda,
using different composition of machines such as:
Conventional mercerizing units (commonly used for flats)
Pad steam machines (commonly used for fabric dyeing)
Impregnation unit with airing and washing facilities
Pad-batch discontinuous units plus washing ranges
Impregnation and tentering units complete of washing compartments,etc
As well as applying a wide variation of process parameters, such as:
Caustic concentration from 18 up to 35 Be’
Caustic temperature from room conditions up to 75 C°
Different auxiliaries into the caustic solution
Caustic impregnation time from a few seconds up to almost a minute time
High and low values of tension warp wise
Tensionless and high tension processes
Shorter and longer dwelling time
Different temperature at washing compartments
Etc
Most of Denim producers, conscious that a certain characteristic on a fabric can set a trend one season but
there are not any assurance of continuity in the years to come, found it too risky to invest in a specific
liquid ammonia machine that can be used ONLY for a specific effect. The liquid ammonia machines involves
a remarkable investment, and if the equipment doesn’t fulfill certain flexibility of applications, it may not
be that useful in incoming years; apart of this fact, liquid ammonia process, its control and ammonia
recovery system need skilled operators and high safety method of utilization. In some countries, its
industrial use is even forbidden. In Italy, i.e., country where the Denim trends are created, most of the
producers opted for tailor made solutions to apply caustic soda rather than to invest in liquid ammonia
machines, and this fact was spread over the whole world. Only some Japanese mills remained very much
preference for the original liquid ammonia treatments, experience and equipment’s available from a deep
practice in fields different than Denims and then applied in this specific production for niche / high price
sector Rest of the producers, except isolated ones, opted for Caustification/mercerizing process.
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Results of Na OH application onto the fabrics- Machinery selection
Production results confirm that application of the Na OH on Denims give a good level of finishing quality
and properties, till certain extend similar to those obtained by liquid ammonia. Correct recipe, use of
proper auxiliaries, fabric preparation, process parameters and a dedicated machine make the results
obtained on Denim fabrics to be widely accepted and popular among Denim mills and garment
manufacturers.
Nowadays, high percentage of Denim finishing is required to be processed through the
Caustification/mercerization of the Denim fabrics, and it is a must for any Denim player to have a machine
for this purpose at their facilities. The popular name of Flat Finish process was adopted by many
technicians, but it is also names as Caustification and/or mercerization.
The question comes automatically in the mind of the decision makers and technical teams: what machine
should be chosen? Which composition is the best one? Which one is giving the best results with the
minimum possible investment? Which unit offers higher flexibility to cover future needs?
Questions certainly not easy to answer on the spot if a proper level of practical experience and knowhow
of the whole production processes are not available. An important part of vision in this field in the years to
come is also required before making a machine selection too.
Normally, investments to be done in such technology are important. Continuous ranges are foreseen for
large production and their dimensions, thus costs, are not indifferent. Many second hand imported
machines have found place in the local denim industry after the collapse of textiles in countries specially
Europe and United States, with relocation of good machines but not specifically for Denims; others, some
“courageous” local suppliers have tried to execute some machine parts just copying some foreign designs,
but missing knowledge of the process is a big gap when technology and knowhow are necessary to build a
correct machine; some producers have opted by putting together “loose parts of existing machines”,
adding the so-called wash tanks, but just getting bad / compromised results. Others have chosen to import
new top branded machines from Europe, with remarkably high cost but with assurance of good
technology and results.
At the same time that some of the mentioned equipment’s started to be used in production, many
problems appeared : difficult process control, not proper effect on treated fabrics, back staining, excessive
width reduction, crease marks, bad looking tone, not proper softness and fabric stability after washing,
etc., to mention some. The simple reason that some of the mentioned units were not specifically studied
for those applications, made the situation even worst to be overcome due to the limitations of the
machinery itself. Adding in many cases wrong process parameters and machine adjustments, lack of
specific knowledge, not proper fabric construction and preparation for such process, all make of the
projects a never ending problematic situation for quality of fabrics and trustable / repeatable results on lot
to lot basis.
SF 20 Super Flat Finish range is born:
The best alternative quality of equipment / price option
The decision taken by one of the leaders Denim mills in Pakistan involved specific expertise, process know
how, machine designing and proper mechanical execution. These were the basis that led to the born of
the named “SF 20 Super Flat Finish unit”, totally and entirely made in Pakistan with the latest technologic
solutions based on many years of experience of the Denim specialist involved in this project.
A Karachi based manufacturing unit known as,
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Karachi Mechanical & Engineering Works on the person of his director Mr. Shoaib Raees
Was the physical executor of the machine, using his accurate work shop,
Very skilled labor as well as proper tooling machines to bring to the unit a very good finishing and on top a
strong and very reliable machine. In cooperation with an Italy based designer and other well-known local
suppliers, the selection of the best high quality materials and parts were used for this machine.
Particularly has to be mentioned the company Gomplast, on the person of Mr. Kaiser Kureshi, who
provided the best available imported rubberizing compounds for padder and caustic section rolls. In fact,
the rubber composites is the well-knownHypalon type, with a wide range of advantages: high resistance to
process conditions, long life of rubber covering, international guarantee and certification on the material
used and local based services with a very good level of technical knowledge.
Machine composition: brief description
Basically, the SF 20 Super Flat Finish unit is the heart of the following machine:
Entry with J-box and pulling calendar
SF 20 Super Flat Finish section
Washing section
Chemical padder
Manual skew unit
Auto skew unit
Can dryer
J box with combined exit batcher/platter
Complete kitchen and mixing/ preparation station
Electrical cabinet for Ac drives and automation all is of European origin and using top branded components
Specifically speaking about the SF 20 Super Flat Finish machine, it has to be mentioned:
The machine is a special tailor made roll type flat finish unit, body entirely made of stainless steel
Boxes for the caustic treatment are completed by upper covers (closed type boxes and padder)
Each box has No. 22 bottom rolls chromed plated, 400 mm diameter, with specially studied and
oriented surface grooves (lathe balanced and worked). Version with Stainless steel roll covers is also
available.
Each box has No. 23 upper hollow rolls, 300 mm diameter, with special rubber cover
Liquor distribution pipes with individual adjustable flow control
Upper hollow rolls can be regulated on their position through the use of eccentric bars with special
high quality Teflon supports; easy assembly and access.
each box has No. 3 compartments independent one from the other, in a way that the NaOH can be
used in 1, 2 or all 3 compartments; depending on the need, a compartment can be used with liquor or
just empty. It permits to limit the amount of bath used (energy savings) thus remaining quite a long
contact time with the caustic, if requested.
the machine has a liquor circulation tank, where facility to heat up or chill the liquor is available (chiller
optional) ; circulation tank is complete of No. 2 filters and No. 2 circulation pumps, inverter controlled.
PLC shows pump flow rate.
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Padder with ebonite and special rubber covered, closed execution; safe operation for workers is very
much considered.
On the first box it can be adjusted not only the “contact time” of Na OH with the fabric, but also
temperature and tension (bottom rolls driven with individual drives on request)
On second box it can be adjusted the dwelling/reaction time and tension, as well part of this box can
be used for “shock washing” with high pressure hot water through the fabric.
Both boxes can be flexibly used as soaping compartments, de-sizing chambers, washing section and as
dyeing unit with air passage for some very fresh special applications. Multipurpose design was
carefully studied to cover all possible needs, with special attention to full control of caustic treatment
process and working conditions
The SF 20 machine is completed, as mentioned in the summarized description, by a top class wash
range, where fabric tension control / crease free operations and high washing off of impurities are the
main characteristics of the range (all boxes with internal counter-flow, intermedious squeezer inside
on upper rolls and upper rolls driven), allowing the reduce rapidly the concentration of alkali onto the
fabric with minimum water consumption, eliminating any risk of back staining, with high energy
savings as well as very low consumption of water and auxiliaries to achieve fabric international
requirements of PH. On line auto skew unit, drying unit and exit make of the machine a very efficient
and complete bulk production trouble free line. Complete automation of the line made of it an
operator friendly production line.
Last but not least, a combination of advantages and very good results are obtained from this SF 20
Super Flat Finish range, such as:
great tension control: fabric passes through the Na OH solution getting “pressed” between bottom and top rolls; fabric never leaves roll surfaces during the Caustification/mercerization process, perfect width control; tension through pneumatic compensator (inside the box itself) of big diameter allow to control easily the warp shrinkage/elongation
special oriented grooves on bottom rolls makes the machine to work in perfect tension less conditions on weft direction (a must in such kind of processes)
very good and controllable warp shrinkages are obtained, indispensable for the final hand feeling of the fabric
Absence of positive shrinkage in width (without the use of any tentering operation), as most of fabrics processed on conventional / unconventional Caustification ranges are suffering. Controllable width shrinkages avoids further processes for width adjustment on stenter (expensive) or uncontrollable width variation on garment process, certainly very uncomfortable parameter
very good fabric hand feel, aspect, “flat finish look” and clean surface comparable to any Denim article coming from famous world producers
Controllable flat finish effect, making it possible to use the same machine in different conditions for any type of fabric (heavy to very light, as well as stretches) by controlling dipping time, dwelling time, temperature and tension. Easy way to change fabric passage when necessary.
multi-function applications and flexibility, a must for nowadays production
high reliability and strength of execution
processing speed up to 60 m/min with high process control and high level of safety, high production capacity
simple, “clean” and well planned design, very good worth for the price
local assistance and after sales service “just in time”
KARACHI MECHANICAL
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The successful run of this unit, its performance and highly efficient operation give to the Pakistani
Denim producers, and soon also to those abroad, not only a very valid, competitive and positive
possibility of choice. The unfortunate but realistic popular general concept that local made machines
are of poor execution and simply a bad copy of branded units (just to meet buyer’s price
requirements) has finally , with SF 20 Super Flat Finish Unit, come to an end in Pakistan. A combination
of high tech machine, process know how, strong execution, high quality of components and parts,
ergonomic design plus local assistance and services are all together a winning point for those who
want to operate high quality equipment at reasonable and fair prices.
Without forgetting that good machines supported by strong know how and technological background of
designers, executors and mentors are an unbeatable combination.
AQUA POWER SUPER DYE FOR ROPE
A. DESCRIPTION OF SUPPLY
DYE BOX& SQUEEZER
Total rope content 10 meters.
Reinforced stainless steel AISI 304 box
5 immersed stainless steel guide rolls diameter 168 mm assembled on self-aligning Nylon bearings, with graphite Teflon box.
1 stainless steel draining valve
Indirect heating through stainless steel coils
Overflow
Stainless steel adjustable comb at rope entry
Automatic temperature control
Pump for bath re-circulation
Vertical 10 ton squeezer roll, the first carbon steel chrome covered Ø290 mm &
the other rubber coated Ø350 mm, pneumatically loaded,
driven by one 10 HP-AC/D C motor
Angular compensator pneumatically loaded for synchronization with the line
Fluorescent illumination. Or any other type
No.2 liquor volume levels (high and low)
Emergency switch
P.T 100
Temperature controller
Pneumatic filter & regulator
Controlling re-circulation pump
Automatic level control (if needed)
B. Electrical board, gear box & motor:
Made in Italy, also available assembled in Pakistan; start up can be done in the presence of European technician with local assistance of KMEW or customer.
Description of electrical supplies varies, always directly proportional to process required, and the No. of boxes offered.
KARACHI MECHANICAL
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SKEW UNIT [Manual] design is heavily
borrowed
(Morrison Machine tool Mfg.)
Frame made of carbon steel S.A 283, total 5N° of
rollers installed, 4N° for skewing and 1N° guider
roller at fabric entry, made of carbon steel
seamless pipe, schedule 40, Ø 160 mm, roller face
2000 mm. installation by using universal bearings
10 N° UC 208 & 2 N° UC 206, total bearing used N°
12.
All guider roller epoxy painted with special
treatment, in order to make sure not to lose paint life in dry/wet/hot/caustic soda
fumes atmosphere.
In order to produce perfect skew effect, there are 6 N° of New TPG & HANG ZHOU
gear boxes;
Installed with great accuracy to bring accurate skewing by moving a wheel installed
at each side of skew unit. Both wheels are connected through intermediate excel, by
mounting bearing support F 206 and using of UC 206 2 N°; these all components are
joined together by using re-conditioned chain coupling Rotex France This skew unit’s
frame is also epoxy painted to avoid any kind of rust.
Stretch meter: Total 3 N⁰ guider rollers epoxy painted 2 N⁰ Pneumatic pistons Ф 80
stroke 500 mm, e-poxy painted steel structure along with gear rack.
J SCARY:
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DRY STACK
INTER MEDIATE SQUEEZER
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FABRIC ENTRY& EXIT
FLUTED PROFILE TURBULENCE ROLLERS
Subject is a revolutionary act with regard to principle of fabric washing, designed by an Italian textile chemist,
highly experienced in machine building and process knowhow.
1. Sheet fabricated fins fused over plain roller produce turbulence in water if the roller is installed at the bottom of wash box, gives gentle mechanical vibration to fabric sheet, helps maximum washing and separating dirt, unfixed dyes and chemicals even starch, which is probably very hard to wash. Roller is suitable for maximum articles of fabric in different GSM. E.g. Lycra, stretch fabric, cotton,
Lennon, Poly even denim.
2. Sheet fabricated fins fused over plain roller enhance chemical reaction while the roller is used for air passage, in order to give fabric sheet reaction time. The roller helps for over dye process, gives the maximum fixation in much less time, comparing the conventional plain rollers, enhance the efficiency of steamer and reactors.
3. The roller is manufactured with great accuracy and even used in yarn sheet dyeing and rope dyeing.
KARACHI MECHANICAL
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PADDER SETS
Karachi Mech….. offers a variety of Padder sets and intermediate squeezers with canopy or opened top for
dyeing, washing, caustic soda, softener, calendaring and pulling. In various loading pressures up to 30 KN.
Designed in Italy and executed with great accuracy in Pakistan
Company offers rubber covering of Gomplast Spain, deals with squeezers, which highly professional and
experienced company ever exist, fortunately they have a local covering unit with all expertise in Karachi. This is
offering the same quality of rubber and professional workmen ship.
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STORAGE TANKS
CHEMICAL KITCHENS